Danfoss APP 53, APP 65, APP 78, APP 86, APP 92 Data sheet

Data sheet
Data sheet
APP Pumps
APP pumps
APP 53 / APP 65 / APP 78 / APP 86 / APP 92
APP 53-86
hpp.danfoss.com
ro-solutions.com
Table of Contents
1. Introduction ............................................................................3
2. Benets.................................................................................3
3. Application examples ...................................................................3
4 Technical data ..........................................................................4
4.1 APP 53-92...............................................................................4
5. Performance curves.....................................................................6
5.1 APP 53 ow at dierent rpm.............................................................6
5.2 APP 65 ow at dierent rpm.............................................................7
5.3 APP 78 ow at dierent rpm.............................................................8
5.3 APP 86 ow at dierent rpm.............................................................9
5.4 APP 92 ow at dierent rpm............................................................10
6. Flushing valve curves ..................................................................11
6.1 APP 53-92 integrated ushing valve ....................................................11
7. Motor requirements....................................................................11
7.1 Calculation factor at 60 barg / 870 psig for APP 53-92....................................11
8. Temperature and corrosion.............................................................12
8.1 Operation..............................................................................12
9. Installation.............................................................................12
9.1 Filtration...............................................................................13
9.2 RO system with direct supply: ..........................................................13
10. Dimensions and connections...........................................................15
10.1 APP 53.................................................................................15
10.2 APP 65 - 92.............................................................................16
10.3 APP 53-92 with IE3 motor, IEC 315S - 4 ..................................................18
10.4 APP 53-92 with IE3 motor, IEC 315M - 4..................................................18
10.5 APP 53-92 with IE3 motor, IEC 315L 1-4 .................................................19
10.6 APP 53-92 with IE3 motor, IEC 315L 2 - 4 ................................................19
11. Pump connections .....................................................................20
11.1 APP 53 - 92.............................................................................20
12. VCM 3” Victaulic........................................................................21
12.1 Technical data .........................................................................21
12.2 Flow versus pressure ...................................................................22
13. Accessories ............................................................................23
14. Service and warranty...................................................................23
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1. Introduction
The Danfoss range of APP high-pressure pumps is designed according to EN 809 for use in RO applications with low viscosity and corrosive uids such as sea water. Danfoss APP pumps are positive displacement pumps with axial pistons that move a xed amount of water in each cycle. Flow is propor­tional to the number of input shaft revolutions (rpm).
1 Housing 2 Shaft 3 Swash plate (non drive end) 4 Retainer plate 5 Piston 6 Cylinder barrel 7 Bleeding / drain plug 8 Valve plate 9 Port plate (non drive end)
Unlike centrifugal pumps, they produce the same ow at a given speed no matter what the discharge pressure. The sectional drawing below illustrates the main components of the APP 53-92 pump range.
10 Center ange 11 Spring cartridge 12 Eye bolt 13 Port plate (drive end) 14 Swash plate (drive end) 15 Shaft seal 16 Motor ange 17 Flushing valve 18 Tail stock screws
2. Benets
3. Application examples Danfoss APP pumps are built into a broad range
Zero risk of lubricant contamination:
- Oil lubricants are replaced with the pumped medium, water, so there is no contamination risk from the pump.
Low maintenance costs:
- Ecient design and all-stainless steel
construction ensure exceptionally long life. When Danfoss specications are met, service intervals of 8,000 hours can be expected. Service is easy, and can be carried out on-site due to the simple design and few parts.
Low energy costs:
- The highly ecient axial piston design provides the lowest energy consumption of any comparable pump on the market.
Easy installation:
- The most compact and lightest design
available.
- The pump can be installed horizon-
tally in dierent positions rotating it around the shaft (see section 10 for example).
of RO desalination plants around the world:
Containerized solutions for hotels, resorts and residences on islands and in coastal regions
No pulsation dampeners necessary due to extremely low pressure pulsation.
- Powered directly by electric motors or combustion engines (with special coupling).
- All pumps are supplied with an integrated ushing valve that allows the uid to ow from inlet to the outlet, when the pump is not running.
High reliability:
- All parts are made of high corrosion resistant materials e.g. Duplex (EN1.4462/ UNS S31803) and Super Duplex (EN1.4410/UNS S32750) stainless steel and carbon reinforced PEEK.
Certied quality:
- Available with positive material idencation (PMI) certication on request.
- ISO 9001, ISO 14001, IAFT 16949
- ATEX certication available for APP S (all Super Duplex) and APP S 674 (API). Please see relevant data sheets.
Mobile systems for humanitarian and military organizations
Onboard systems for ships and yachts
Oshore platforms for the oil and gas industry
Municipal and regional waterworks
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4.1 APP 53-924 Technical data
Pump size APP 53/1500 APP 65/1500 APP78 /1500 APP 86/1700 APP 92 /178 0
Code number 180B7806 180B7807 180B7808 180B7809 180B7810
Geometric displacement
Pressure
Max. outlet pressure (MAWP)
Min. inlet operating pressure
Max. inlet operating pressure
Max. inlet pressure peak
Min. outlet pressure
Speed
Min. speed continuous
Max. speed continuous
Flow
Min. ow
700 rpm at max. pressure
1000 rpm at max. pressure
1200 rpm at max. pressure
1500 rpm at max. pressure
1700 rpm at max. pressure
1780 rpm at max. pressure
Eciency
1000 rpm
1200 rpm
1500 rpm
170 0 rp m
178 0 rp m
cm³/rev. 617 778 888 888 888 in³/re v. 37. 7 47. 3 54.2 54.2 54.2
1)
barg 83 83 83 70 70
psig 1,200 1,200 1,200 1,015 1,015
barg 2 2 2 2.5 3.5
psig 29 29 29 36 50
barg 5 5 5 5 5
psig 73 73 73 73 73
barg 10 10 10 10 10
psig 145 145 145 145 145
barg 30 30 30 30 30
psig 435 435 435 435 435
rpm 700 700 700 700 700
rpm 1,500 1,500 1,500 1,700 1,780
m³/ h 24 32 36 36 36
gpm 106 141 15 8 158 158
m³/ h 24 32 36 36 36
gpm 106 141 15 8 158 158
m³/ h 35 45 52 52 52
gpm 15 4 198 228 228 228
m³/ h 42 54 62 62 62
gpm 187 238 275 275 275
m³/ h 53 68 78 78 78
gpm 235 299 345 345 345
m³/ h 88 88
gpm 387 387
m³/ h 92
gpm 405
3)
% 88 88 89 89 89
3)
% 89 89 90 89 89
3)
% 88 89 89 88 88
3)
% 88 88
3)
% 87
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Pump size APP 53/1500 A PP 65/150 0 APP 78 /1500 APP 86/1700 APP 92/178 0
Code number 180B7806 180B7807 180B7808 180B7809 18 0B7810
Technical specications
2)
Media temperature
Ambient temperature
Weight (dry)
Weight (operation)
°C 2–50 2-50 2–50 2-50 2-50
°F 36 –122 36-122 36 –122 36 -122 36-12 2
°C 0–50 0-50 0–50 0-50 0-50
°F 32–122 32-122 32–122 32-122 32-122
kg 196 196 196 196 196
lb 432 432 432 432 432
kg 204 204 204 204 204
6)
lb 450 450 450 450 450
Sound pressure level
Footprint with IE3 motor
db(A) 84-95 84-95 84-93 84-96 84-96
1.49 1.49 1. 50 1.50 1.50
4)
Foot² 16.0 17. 0 16.1 16.1 16 .1
Typical motor size
Max.speed at max. pres-
5)
sure
1)
Max. allowable working pressure at continuous operation. The pump is designed according to EN809, i.e. to
withstand hydrostatic test pressure (HTP) of 1.3 x MAWP. For lower and higher pressure, please contact Danfoss.
2)
Dependent on the NaCI concentration.
3)
Typical eciency at max. pressure after a system has been commissioned and run in.
4)
Maximum area covered with recommended IE3 motor congurations (excl. of space to service pump)
5)
IE3 and NEMA motors, 4-pole, current insulated ND non drive end bearing
6)
Operating with water
kW 132 160 160 200 200
HP 200 250 250 300 300
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100,00
120,00
140,00
160,00
180,00
200,00
220,00
240,00
260,00
280,00
300,00
320,00
340,00
360,00
380,00
400,00
Flow [gpm]
Speed [RPM]
5. Performance curves
If the ow required and the rotation speed (rpm) of the pump is known, it is easy to select the pump, tting the application best, by using the diagram below.
5.1 APP 53 ow at dierent rpm
90,00
85,00
80,00
75,00
70,00
65,00
60,00
55,00
50,00
Flow [m3/h]
45,00
40,00
35,00
30,00
25,00
20,00
Furthermore, this diagram shows that the ow can be changed by changing the rotation speed of the pump. The ow/rpm ratio is constant, and the “required” ow can be obtained by changing the rotation speed to a corresponding value. Thus, the required rpm can be determined as:
Required ow x Rated rpm
Required rpm =
Rated ow
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Speed [RPM]
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20,00
25,00
30,00
35,00
40,00
45,00
50,00
55,00
60,00
65,00
70,00
75,00
80,00
85,00
90,00
Flow [m3/h]
Speed [RPM]
100,00
120,00
140,00
160,00
180,00
200,00
220,00
240,00
260,00
280,00
300,00
320,00
340,00
360,00
380,00
400,00
Flow [gpm]
Speed [RPM]
5.2 APP 65 ow at dierent rpm
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20,00
25,00
30,00
35,00
40,00
45,00
50,00
55,00
60,00
65,00
70,00
75,00
80,00
85,00
90,00
Flow [m3/h]
Speed [RPM]
5.3 APP 78 ow at dierent rpm
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400,00
380,00
360,00
340,00
320,00
300,00
280,00
260,00
240,00
Flow [gpm]
220,00
200,00
180,00
160,00
140,00
120,00
100,00
Speed [RPM]
AI167386503010en-001301
100,00
120,00
140,00
160,00
180,00
200,00
220,00
240,00
260,00
280,00
300,00
320,00
340,00
360,00
380,00
400,00
Flow [gpm]
Speed [RPM]
5.3 APP 86 ow at dierent rpm
90,00
85,00
80,00
75,00
70,00
65,00
60,00
55,00
50,00
Flow [m3/h]
45,00
40,00
35,00
30,00
25,00
20,00
Speed [RPM]
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20,00
25,00
30,00
35,00
40,00
45,00
50,00
55,00
60,00
65,00
70,00
75,00
80,00
85,00
90,00
95,00
100,00
Fl ow [m3/h]
Speed [RP M]
100,00
120,00
140,00
160,00
180,00
200,00
220,00
240,00
260,00
280,00
300,00
320,00
340,00
360,00
380,00
400,00
420,00
Fl ow [gpm]
Speed [RP M]
5.4 APP 92 ow at dierent rpm
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6. Flushing valve curves
6.1 APP 53-92 integrated ushing valve
Pressure [barg]
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0
0
100
200
300
400
500
Flow [l/min]
600
The power requirements can be determined using one of the following guiding equations:7. Motor requirements
3
l/min x barg 16.7 x m
/h x barg 0.35x gpm x psig Required power = [kW] or [kW] or Calc. factor Calc. factor Calc. factor
1 hp = 0.75 kW 1 gpm = 3.79 l/min
3
1 m
/h = 4.40 gpm 1 kW = 1.34 hp 1 l/min = 0.26 gpm 1 gpm = 0.23 m
3
/h
7.1 Calculation factor at 60 barg / 870 psig for APP 53-92
Name rpm
APP 53 150 0 528
APP 65 1500 534
APP 78 1500 534
APP 86 1700 528
APP 92 178 0 522
Calculation
factor
[Hp]
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8. Temperature and corrosion
8.1 Operation
The chart below illustrates the corrosive resistance of dierent types of stainless steel related to NaCl concentration and temperature.
All wetted parts of the APP pump are made of Duplex or Super Duplex.
º
80
C
Duplex
70
60
50
316L
40
30
20
100
160 1600
1000
10 000
16000
If the water pump is operated at high salinity always ush the water pump with fresh water at operation stop in order to minimize the risk of crevice corrosion.
NaCI vs. temperature
Super Duplex
-
100 000
160000
CI ppm
NaCI ppm
9. Installation See example below on how to mount the pump and connect it to an electric motor or combus­tion engine (special coupling). For further instruction on installation of coupling see APP Pump Instruction 180R9368.
If alternative mounting is required. please contact your Danfoss sales representative for further information.
Note: Do not add any axial or radial loads to the pump shaft.
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9.1 Filtration
Proper ltration is crucial for the performance, maintenance and warranty of your pump.
Protect your pump, and the application in which it is installed, by always ensuring that all ltration specications are met, and by always changing lter cartridges according to schedule.
Since water has very low vicosity, Danfoss APP pumps have been designed with very narrow clearances in order to control internal leakage rates and improve component performance.
To minimize wear on the pump, it is therefore essential to lter inlet water properly.
The main lter must have a ltration eciency of
99.98% at 10 m. We strongly recommend that you always use precision depth lter cartridges rated 10m abs. ß
≥5000.
10
Please note that we do not recommend bag lters or string-wound lter cartridges, which typically have only 50% ltration eciency. This means that out of the 100,000 particles that enter such lters, 50,000 particles pass right through; compare this to precision depth lters that are 99.98% ecient, and only allow 20 of the same 100,000 particles to pass through.
For more information on the importance of proper ltration, including explanation of ltration principles, denitions and guidance on how to select the right lter for your pump, please consult our Filtration information and specications (Danfoss document number 521B1009).
Noise
Since the pump unit is typical mounted on a frame or bell housing the overall noise level can only be determined for a complete system. To minimize vibrations and noise throughout the system, it is therefore very important to mount the pump unit correctly on a frame with anti-vibration-dampeners, and to use exible hoses rather than metal pipes where possible.
The noise level is inuenced by:
Pump speed: High rpm generates more uid/structure borne pulsations/vibrations than low rpm, because of higher frequency.
Discharge pressure: High pressure generates more noise than low pressure.
Pump mounting: Rigid mounting generates more noise than exible mounting, because of structure­borne vibrations. Be sure to use dampeners when mounting.
Connections to pump: Pipes connected directly to the pump make
more noise than exible hoses, because of structure-borne vibrations.
Variable frequency drives (VFD): Motors regulated by VFDs can produce more noise if the VFD does not have the right settings.
9.2 RO system with direct supply:
Inlet line:
a) Dimension the inlet line to obtain mini mum pressure loss (large ow, minimum pipe length, minimum number of bends/ connections, and ttings with low or no pressure losses) .
Inlet lter:
b) Install an inlet lter (1) in front of the APP pump (2). Please consult section 9.1, “Filtration” for guidance on how to select the right lter. Thoroughly clean pipes and ush system prior to start-up.
Inlet pressure: c In order to eliminate the risk of cavitation and other pump damage, pump inlet pressure must always be maintained according to specications described in item 4 about technical data.
Low pressure relief valve:
d) Install a low pressure relief valve (9) in order to avoid system or pump damage in case the pump stops momentarily or is spinning backwards.
Monitoring pressure switch: e Install a monitoring pressure switch (3)
between the lter (1) and the pump inlet. Set the minimum inlet pressure according to specications described in item 4 about technical data. If the inlet pressure is lower than the minimum pressure set, the monitoring pressure switch must prevent the pump from starting or from running.
Hoses:
f) Always use exible hoses (4) to minimize vibrations and noise. Please consult the Danfoss Hoses and hose ttings data sheet (521B0909) for guidance.
Flushing valve: g) For easy system lling and ushing, the APP pump has an integrated valve (6).
Non-return valve: h) A non-return valve (7) in outlet can be installed in order to avoid backspin of the pump. The volume of water in the membrane vessel works as an accumulator and will send ow backwards in case the pump stops momentarily.
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High pressure safety or relief valve:
i) As the Danfoss APP pump begins to create pressure and ow immediately after start-up and regardless of any counter pressure, a safety or pressure relief valve (8) should be installed after the non-return valve to prevent system damage and to avoid high pressure peaks.
Note: If a non-return valve is mounted in the inlet line, a low-pressure relief valve is also required between the non-return valve and pump as protection against high-pressure peaks.
Feed
Media filter
PI
PI
PI P I
Fresh water
permeat flush
M
PT
PI
Brine
Permeate
PI
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connections
10.1 APP 5310. Dimensions and
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10.2 APP 65 - 92
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APP 65 - 92
AI167386503010en-001301
The APP 53-92 connections (inlet and outlet) can be adjusted in intervals of 45 degrees. Please see typical installations with check valve VCM 92 mounted in the outlet port in the drawing below. Non-standard congurations are available on request. For adjustment on site, please see Installation, Operation and Maintenance Manual or contact Danfoss.
Non-standard conguration, turned 90 degrees left.
Non-standard conguration, turned 45 degrees left.Standard conguration
Non-standard conguration, turned 180 degrees .
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10.3 APP 53-92 with IE3 motor, IEC 315S - 4
10.4 APP 53-92 with IE3 motor, IEC 315M - 4
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10.5 APP 53-92 with IE3 motor, IEC 315L 1-4
10.6 APP 53-92 with IE3 motor, IEC 315L 2 - 4
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11. Pump connections
11.1 APP 53 - 92
Use only Style 77DX coupling or equivalent.
3” Victaulic OSG LP Inlet
3” Victaulic OSG HP Outlet
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Connection
3” Inlet connector
3” outlet connector
1
) The installation instuction for Style 77DX is located in the Victaulic document I-100 Field Installation
Diameter
(A)
87. 8 m m
(3.46 inch)
87. 8 m m
(3.46 inch)
Victaulic
3” Vic. OSG
3” Vic. OSG
(B)
1)
Length
(C)
61.0 mm (2.40”)
65.0 mm
(2.56”)
Material Max. Pressure Code number
Super
Duplex
Super
Duplex
10 barg
(145 psig)
80 barg
(1160 psig)
180Z1991
180Z1992
Handbook (htpp://static.victaulic.com)
AI167386503010en-001301
12. VCM 3” Victaulic
The non-return valve is designed for use in Seawater Reverse Osmosis (SWRO) membrane systems. In case the high-pressure pump stops momentarily, the volume of water in the membrane vessel may work as an accumulator and will send ow backwards.
When using multiple pumps in parallel, the non-return valve
12.1 Technical dat a
prevents the water from one pump to run into the parallel-coupled pumps at start-up. The VCM 92 is prepared for easy installation on the high pressure outlet of APP 53-92, series 08 or higher..
Use only Style 77DX coupling or equivalent.
3” Vic. OSG
3)
Length mm (inch)
180.5 (7.10)
Material2
Super
Duplex
Diameter
valve
)
1)
mm (inch)
87. 7
(3.45)
Typ e Connection
VCM 92
1)
The check valve is mounted directly in the outlet port with a ange with 8 screws M12 x 25.
2)
Wetted parts materials: Super Duplex, PEEK, PP, Hasteloy; FKM, NBR
3)
The installation instuction for Style 77DX is located in the Victaulic document I-100 Field Installation
3” outlet check
Victaulic (outlet connection)
Max.
2)
pressure barg (psig)
83 (1.200) 180H0058
Code number
Handbook (htpp://static.victaulic.com)
VCM VCM 92
Min. ow continously
Max. ow continously
Max pressure MAWP
Opening pressure barg 0.05- 0.08
Pressure loss at max. ow barg < 0.45
m/h 20
gpm 88
m/h 92
gpm 405
barg 83
psig 1200
psig 0.73 -1.16
psig < 6.5
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0
0,05
0,1
0,15
0,2
0,25
0,3
0,35
0,4
0,45
0,5
20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
dP [ bar ]
Flow [ m3/h ]
Flow versus pre ssure for VCM 92
1
2
3
4
5
6
7
80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440
dP [ PSI ]
Flow [ GPM]
Flow versus pre ssure for VCM 92
1. Valve housing (Super Duplex)
2. Valve guide and valve stop (Super Duplex, PEEK and PP)
3. Valve Cone (Super Duplex)
5. Spring (Hasteloy)
6. O-ring (NBR)
7. O-ring (FKM 75)
8. O-ring (NBR)
12.2 Flow versus pressure Pressure drop curves for check valve VCM 92
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13. Accessories
14. Service and warranty
Accessories Typ e Code num-
Coupling APP 53 - APP 92 IEC 315 Diameter: motor Ø80 mm, pump Ø50 180Z40 66 Coupling APP 53 - APP 92 IEC 280 Diameter: motor Ø75 mm, pump Ø50 180Z4081 Coupling kit APP 53 - APP 92 incl. bell housing IEC 315 Ø80/Ø50. IEC 315 Ø660/310 180Z4083 Coupling kit APP 53 - APP 92 incl. bell housing IEC 280 Ø75/Ø50. IEC280 Ø550/265 180Z4082 Base frame incl. vibration dampeners IEC 315 180Z06 61
Warranty
Danfoss APP pumps are designed for long operation, low maintenance and reduced lifecycle costs.
Pump shutdown:
The APP pumps are made of Duplex/Super Duplex materials with excellent corrosion properties. It is, however, always recommended
to ush the pump with freshwater when the Provided that the pump has been running according to the Danfoss specications, Danfoss guarantees 8,000 hours service-free operation, however, max. 18 months from date of production.
system is shut down.
When stopping the pump for more than 1 day
ush the pump for 10 sec. Flushing through the
ushing valve of the pump without rotating the
pump is not enough for cleaning the inside of
the pump. If Danfoss recommendations concerning system-design are not followed, it will strongly inuence the life of the APP pumps. Other factors that aect pump performance and lifetime include:
The pump can be ushed with biocide like the
membranes. The biocide must be compatible
with the materials used in our pump (materials
can be found in the parts list in the instruction
and operational manual).
- Insucient ltration
- Insucient bleeding and venting
- Running the pump at speed outside specications.
Repair
In case of irregular function of the APP pump,
please contact Danfoss High Pressure Pumps.
- Supplying the pump with water at temperature higher than recommended.
- Running the pump at inlet pressure outside specications.
- Running the pump at outlet pressure outside the specications.
- Wrong direction of rotation.
Maintenance
After 8,000 hours of operation it is strongly recommended to inspect the pump and change any worn parts, e.g. pistons and shaft seal. This is done in order to prevent a potential breakdown of the pump. If the parts are not replaced, more frequent inspection is recommended according to our guidelines.
ber
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